The invention relates to a casting mold, in particular for use in cold casting methods, which is produced with the aid of a powder-based layering method, the final casting mold having a treated surface.

Benzyl ether-type phenolic resins are useful in either a phenolic resin polyurethane cold-box (PUCB) process or a phenolic resin polyurethane no-bake (PUNB) process. The benzyl ether-type phenolic resins contain at least one formaldehyde scavenger in the form of a beta-dicarbonyl compound, and an alpha-carbonyl-carboxyl compound, particularly glyoxylic acid, binders based on these phenolic resins, and isocyanate compounds having at least two isocyanate groups. The resins having the inventive concept exhibit low free formaldehyde content. The inventive concept extends to molding material blends containing the binder, and a method for producing cores, molds or risers.

A method of making sand casting moulds with a protective coating for a multiple process of reactive moulding of insulation components and products made by filling up a mould cavity with polymer materials, including composites, based particularly on epoxy resins or composites based on cellulose materials, the method wherein the process of infiltration of the mould structure is performed chemically by soaking through the raw mould structure with chemosetting or thermosetting material. The application of a protective layer on external surfaces of a sand casting mould is done by means of any spraying, immersion or deposition method, whereas material with anti-adhesive properties is used for the protective coating in the form of organic chemosetting, thermosetting, light-curing material or in the form of inorganic material, including metal.

A method of fabricating a mold includes 3D printing a first shell using a first material, the first shell having a first interior surface and a first exterior surface, and 3D printing a second shell using a second material different from the first material, the second shell having a second interior surface and a second exterior surface wherein the second interior surface generally conforms to the first exterior surface. The first material may be thermally conductive and the second material may be thermally insulative, and the first and/or second shell may include at least one thermal regulation element formed therein.

According to some aspects, a method is provided of casting an object from a mold, the method comprising obtaining a mold comprising a hollow shell of rigid material, the material comprising a thermoset polymer having a plurality of pores formed therein, providing a metal and/or ceramic slurry into an interior of the mold, exposing at least part of the mold to a low pressure environment so that a net flow of gas is produced from the interior of the mold into the low pressure environment. According to some aspects, a method of forming a porous mold is provided. According to some aspects, a photocurable liquid composition is provided, comprising a liquid photopolymer resin, particles of a solid material, in an amount between 30% and 60% by volume of the composition, and a water-soluble liquid.

The present disclosure generally relates to integrated core-shell investment casting molds that provide filament structures corresponding to cooling hole patterns in the surface of the turbine blade or stator vane, including in locations that are inaccessible due to the presence of protrusion patterns. The filament structures also provide a leaching pathway for the core portion after metal casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.

A method of manufacturing a roll type imprint master mold including disposing a base layer on a substrate including a first area and a second area adjacent to the first area, disposing an inorganic insulation layer on the base layer, forming a first mask pattern and a first resin pattern in the first area, forming a pattern layer by etching the inorganic insulation layer using the first resin and the first mask patterns as a mask, removing the first resin and the first mask patterns, forming a second mask pattern and a second resin pattern in the second area, forming a pattern layer by etching the inorganic insulation layer using the second resin and the second mask patterns as a mask, removing the second resin and the second mask patterns, separating the base layer from the substrate, and attaching the base layer onto a roll body.

A method for inorganic binder casting, comprising: selecting a Shape-Forming Material based on pre-determined manufacturing and shape characteristics, selecting a casting shape based on pre-determined design characteristics, and forming the Shape-Forming Material into a mold. The mold is coated with an inorganic binder solution at a pre-defined weight ratio and is dehydrated the Shape-Forming Material. The method further comprises pouring a hot liquid metal into the mold and allowing said hot liquid metal to cool to form a molded part. The Shape-Forming Material may be washed from said molded part with a solvent, the inorganic material and Shape-Forming Material reclaimed, reused, and the Shape-Forming Material reformed to a mold. The method further comprises recreating a liquid inorganic binder solution using the reclaimed inorganic material and recoating the Shape-Forming Material with the reclaimed inorganic binder solution.

A laminate nanomold includes a layer of perfluoropolyether defining a cavity that has a predetermined shape and a support layer coupled with the layer of perfluoropolyether. The laminate can also include a tie-layer coupling the layer of perfluoropolyether with the support layer. The tie-layer can also include a photocurable component and a thermal curable component. The cavity can have a broadest dimension of less than 500 nanometers.

According to some aspects, a method is provided of casting an object from a mold, the method comprising obtaining a mold comprising a hollow shell of rigid material, the material comprising a thermoset polymer having a plurality of pores formed therein, providing a metal and/or ceramic slurry into an interior of the mold, exposing at least part of the mold to a low pressure environment so that a net flow of gas is produced from the interior of the mold into the low pressure environment. According to some aspects, a method of forming a porous mold is provided. According to some aspects, a photocurable liquid composition is provided, comprising a liquid photopolymer resin, particles of a solid material, in an amount between 30% and 60% by volume of the composition, and a water-soluble liquid.